S10 Pickup, Sonoma 2000-2004

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.2L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Use a back-up wrench on the fuel rail return fitting to prevent it from turning.


    NOTE
    Because each injector is calibrated for a specific flow rate, make sure you only replace fuel injectors using an IDENTICAL part number to the old injectors.



    Negative battery cable
     
    Intake manifold, if necessary
     
    Fuel injector electrical connections by pushing in the wire connector clip and gently pulling on the connector
     
    Fuel feed inlet pipe from the rail
     



    Fuel return pipe from the fuel pressure regulator
     
    Fuel pressure regulator
     
    Fuel rail attaching bolts and lift the fuel rail assembly from the cylinder head
     
    Fuel rail by moving the rail toward the front of the engine
     
    Fuel injector retaining clip
     
    Fuel injector
     



    Click image to see an enlarged view

    Fig. Exploded view of a typical fuel injector-2.2L engine

  4.  

To install:


NOTE
When installing the injector care should be taken not to tear or misalign O-rings.

  1. Lubricate the injector O-ring seals with clean engine oil and install them injector.
  2.  
  3. Install or connect the following:
    NOTE
    Use a back-up wrench on the fuel rail return fitting to prevent it from turning.


    NOTE
    Rotate the fuel injectors as necessary to avoid stretching the wire harness.



    Upper O-ring, lower back-up O-ring and lower O-ring
     
    Fuel injector to the fuel rail
     
    Fuel injector retaining clip
     
    Fuel rail and insert it into the cylinder head
     
    Fuel rail retaining bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Fuel pressure regulator
     



    Return pipe to the fuel pressure regulator. Tighten the fuel pipe nut to 22 ft. lbs. (30 Nm).
     
    Fuel feed inlet pipe to rail
     



    Injector electrical connections
     
    Intake manifold, if removed
     
    Negative battery cable
     

  4.  
  5. Inspect for leaks as follows:
    1. Turn the switch to the ON position for 2 seconds.
    2.  
    3. Turn the ignition switch OFF for 10 seconds.
    4.  
    5. Turn the ignition switch to the ON position and check for leaks.
    6.  

  6.  

4.3L Engine
  1. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    When disconnecting the poppet nozzles, note the sequence for correct poppet nozzle placement to each cylinder.


    NOTE
    Each injector is calibrated. When replacing the fuel injectors, be sure to replace it with the correct injector.



    Negative battery cable
     
    Fuel meter body electrical connection and the fuel feed and return hoses from the engine fuel pipes
     
    Upper manifold assembly
     



    Poppet nozzle out of the casting socket by squeezing the poppet nozzle locking tabs together while lifting the nozzle out of the casting socket
     
    Fuel meter body by releasing the locktabs
     



    Lower hold-down plate and nuts
     

  4.  
  5. While pulling the poppet nozzle tube downward, push with a small prytool down between the injector terminals and remove the injectors.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel meter assembly, including the injectors-4.3L engine

  6.  

To install:

  1. Lubricate the new injector O-ring seats with engine oil.
  2.  
  3. Install or connect the following:
    CAUTION
    To reduce the risk of fire or injury ensure that the poppet nozzles are properly seated and locked in their casting sockets


    NOTE
    The fuel meter body assemblies are numbered to indicate poppet nozzle order.



    O-rings on the injector
     
    Fuel injector into the fuel meter body injector socket.
     
    Lower hold-down plate and nuts. Torque the nuts to 27 inch lbs. (3 Nm).
     
    Fuel meter body assembly into the intake manifold. Torque the fuel meter bracket retainer bolts to 88 inch. lbs. (10 Nm).
     



    Fuel meter body into the bracket and lock all the tabs in place
     



    Poppet nozzles into the casting sockets
     
    Electrical connections
     
    New o-ring seals on the fuel return and feed hoses
     
    Fuel feed and return hoses and tighten the fuel pipe nuts to 22 ft. lbs. (30 Nm)
     
    Negative battery cable
     

  4.  
  5. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  6.  
  7. Install the manifold plenum.
  8.  

  1. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.


    NOTE
    Before removal, clean the fuel meter body assembly with a spray type engine cleaner, GM X-30A or the equivalent, if necessary. Follow the package instructions. DO NOT soak fuel meter body assemblies in liquid cleaning solvent.



    Negative battery cable
     
    Upper manifold assembly
     

  6.  
  7. Cover the fuel injector sockets to prevent dirt and other debris from entering the open fuel passages.
    NOTE
    When disconnecting the fuel injectors, note the sequence to ensure correct injector placement to each cylinder.

  8.  
  9. Lightly pull on the injector tube and use a small screwdriver to carefully release the injector from the manifold.
  10.  
  11. Remove the fuel meter body from the bracket by releasing the lock tabs on the bracket Remove the injector retainer lock nuts and retainer.
    NOTE
    Be careful when removing the fuel injectors to avoid damaging the electrical connector terminals. The fuel injector is serviced as a complete assembly only. Also, since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector cleaning is not recommended.

  12.  
  13. While pulling the fuel injector downward, push with a small tip punch down between the injector terminals until the injector is removed.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel meter assembly, including the injectors-4.3L engine

  14.  

To install:

  1. Lubricate the new injector O-ring seats with engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    The fuel meter body assemblies are numbered to indicate poppet nozzle order.



    O-rings on the injector
     
    Fuel injector into the fuel meter body injector socket.
     
    Retainer and the injector retainer lock nuts. Tighten the nuts to 27 inch lbs. (3 Nm).
     
    Fuel meter body in the intake manifold. Push the fuel meter body into the bracket. Make sure all of the tabs are locked into place
     



    Poppet nozzles into the casting sockets. Inspect the injectors in order to ensure they are firmly seated and locked in the casting sockets.
     
    Upper intake manifold
     
    Negative battery cable
     

  4.  
  5. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  6.  

 
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